Magnetic tape, its cleaning method, and optical servotrack forming/cleaning apparatus

ABSTRACT

A magnetic tape which comprises a nonmagnetic support, a magnetic layer which is formed on one surface of the nonmagnetic support, and a backcoat layer which comprises a binder and nonmagnetic powder containing carbon black as a component and which is formed on the other surface of the nonmagnetic support, having pits for optical servo formed thereon, characterized in that the average of the reflectance on the flat portion of the backcoat layer is 8.5% or higher, and that the maximum rate of fluctuation of the reflectance on the flat portion, depending on a position of the magnetic tape: 
       [Maximum of absolute value of (Reflectance−Average reflectance)]×100/(Average reflectance)
 
     is 10% or lower. This magnetic tape is high in the initial S/N of the servo signal, and also high in the S/N of the servo signal found after the magnetic tape is run twice.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of co-pending application Ser. No.12/862,504 filed on Aug. 24, 2010. Application Ser. No. 12/862,504 is aDivisional of co-pending application Ser. No. 10/343,432 (U.S. Pat. No.7,803,471) filed on Mar. 31, 2003, which is the National Phase of PCTInternational Application No. PCT/JP2001/11610 filed on Dec. 28, 2001,which claims priority under 35 U.S.C. 119(a) to Patent Application No.2000-403216 filed in Japan on Dec. 28, 2000 and Patent Application No.2000-403217 filed in Japan on Dec. 28, 2000. The entire contents of allof the above applications are hereby incorporated by reference into thepresent application.

TECHNICAL FIELD

The present invention relates to a magnetic tape in which pits foroptical servo tracks are formed on a backcoat layer, a method forcleaning a magnetic tape, and an apparatus for forming and cleaningoptical servo tracks.

BACKGROUND ART

Magnetic tapes have found various applications in audio tapes,videotapes, data backup tapes for computers, etc. In particular, in thefield of magnetic tapes for data-backup (or backup tapes), tapes havingmemory capacities of several tens GB or more per one reel arecommercialized in association with increased capacities of hard discsfor back-up. Therefore, it is inevitable to increase the capacity ofthis type of a tape for data-backup so as to correspond to a furtherincreased capacity of a hard disc. It is also necessary to increase thefeeding speed of tape and a relative speed between the tape and heads inorder to quicken the access speed and the data transfer speed.

To increase the capacity of tape for data-backup per one reel, thefollowing are necessary: (1) the length of a tape per reel is increasedby decreasing the total thickness of the tape; (2) the thicknessdemagnetization is decreased to shorten the recording wavelength byforming a magnetic layer with a thickness as very thin as 0.3 μM orless; and (3) the recording density in the tape widthwise direction isincreased by narrowing the widths of the tracks to 15 μm or less.

When the thickness of the magnetic layer is reduced to 0.3 μm or less,the durability of the tape tend to lower. Therefore, at least one primerlayer is provided between a nonmagnetic support and the magnetic layer.When the recording wavelength is shortened, the influence of spacingbetween the magnetic layer and the magnetic heads becomes serious. Thus,if the magnetic layer has large projections or dents, an outputdecreases due to spacing loss, and thus an error rate increases.

When the magnetic layer is formed with a thickness so thin as 0.3 μm orless and concurrently the recording wavelength is decreased, magneticflux leakage from the magnetic recording medium is decreased. Therefore,it is preferable to use reproducing heads which make use ofmegnetoresistance elements capable of achieving high output from verysmall magnetic fluxes (hereinafter, referred to as MR heads). When therecording density in the tape-widthwise direction is increased bynarrowing the width of the tracks (the width of data tracks on whichsignals are recorded) to 15 μm or less, reproduction output decreasesdue to off-track. To overcome such a problem, track servo becomesnecessary.

One of such track servo systems is an optical track servo system, inwhich pits for optical servo are formed by irradiation with laser beamsor by depression with a stamper, and such pits are optically detectedfor servo tracking.

As other optical track servo systems of this type, JP-A-03-141087discloses the formation of pits for optical servo on the magnetic layerof a floptical disc (an optical servo track type floppy disc), andJP-A-11-339254 and JP-A-11-213384 disclose the formation of pits foroptical servo are formed on the backcoat layer of a magnetic tape.

In the optical track servo systems in which pits for optical servo areformed on the backcoat layer, the track servo is performed by detectinga difference in reflectance between the pits and the flat portion of thebackcoat layer. In particular, when the backcoat layer having such pitsis irradiated with light, light randomly reflects on the pits, andtherefore, the intensity of reflected light which enters an opticaldetector is low. On the other hand, light regularly reflects on the flatportion, and thus, the intensity of reflecting light is high. Thissystem makes use of such a difference to trace the servo tracks formedas the pits. Specifically, interlocking with the servo tracking on thebackcoat layer, the magnetic head which records or reproduces signals onor from the magnetic layer is moved to perform servo tracing onmagnetically recording tracks.

According to this system, if the pits for optical servo are formed byirradiation with conventional laser beams, the intensity of lightrandomly reflecting on the pits can be sufficiently lowered. However,the intensity of light which reflects on the flat portion of thebackcoat layer of a conventional magnetic tape is low, and thereflectance on the flat portion largely fluctuates depending on a siteof the magnetic tape. Thus, it is impossible to sufficiently increasethe ratio of S/N of optical servo signals. The reason therefor is thatkeen attentions are paid to only the tape running performance on thebackcoat layer of the a conventional magnetic tape, but not to thereflectance thereon.

In case where pits are formed in a backcoat layer by irradiation withlaser beams or by depression with a stamper, the peripheries (or theedges) of the pits are inevitably raised, which causes the followingproblems. In case where the total thickness of a magnetic tape is 6 μmor less, the rigidity of the tape (i.e., ET³ in which E is a Young'smodulus of a tape, and T is a total thickness of the tape) decreases,and therefore, it is needed to decrease the winding tension for the tapewhich is running. In this case, if the specific positions of themagnetic tape are raised as described above, the track-formed portion ofthe tape wound onto a reel becomes extremely high, which results in adisorder in the winding of the tape.

In addition, if the tape has the raised portions as described above,they are pressed against the side of the recording layer (magneticallyrecording surface) of the magnetic tape, so that the surface of therecording layer becomes uneven, which results in low reproductionoutput. In case of a magnetic disc employing the optical servo tracksystem, such winging as is made on the tape is unnecessary, andtherefore, such disorder in the winding or the pressing by the raisedportions do not occur, even though the peripheries of the pits foroptical servo are raised. That is, these problems are peculiar to themagnetic tapes. To solve these problems, it is desirable to decrease theheight of the raised portions of the tape to not higher than the heightof the maximum projection of the flat portion thereof.

When the pits are formed on the backcoat layer by irradiation with laserbeams, the coating surface of the backcoat layer is baked off by theenergy of laser beams so as to form a pattern of pits. This methodprovides higher productivity, however, has a problem in that thenumerous particles of burnt residues as the result of the laser bakingfor forming a pattern, undesirably, adhere to the pits and theirperipheries. If the burnt residues are left as they are, they cause notonly contamination of the tape-running system but also decrease in theratio of S/N of optically read signals on the backcoat layer and thedropping-out of the magnetic layer due to the adhesion of the burntresidues. Further, the reflectance on the flat portion of the backcoatlayer decreases, so that the reflectance in the lengthwise direction ofthe tape largely fluctuates. This fluctuation also decreases the ratioof S/N of optically read signals. Therefore, the removal of such burntresidues is necessary.

It is known that burnt residues which remain after the formation of pitsfor optical servo by irradiation with laser beams are removed usingsolid CO₂, which has been used for removing such burnt residues from afloptical disc having pits for optical servo formed thereon (U.S. Pat.No. 5,419,733). In case of a floptical disc, the surface area to becleaned is limited, and the solid CO₂ can easily be sprayed to clean thesurface by rotating the disk a number of times at a high velocity.

If this method is applied to clean a magnetic tape, the total surfacearea of the lengthy tape to be cleaned is enormous, and the amount ofsolid CO₂ blown onto the tape a lot of times becomes far larger ascompared with the disc. Therefore, the cleaning efficiency is poor. Themagnetic tape confronts a further problem from which the floptical dischas never suffered: that is, the burnt residues remaining after theformation of the servo pattern by irradiation with laser beams adhereand transfer when the magnetic tape is again wound, and such burntresidues, in turn, adhere to the drive guide roller and the magneticheads.

Alternatively, the surface of the magnetic tape is cleaned, for example,by allowing a tissue cleaning tape to contact with the front and backsurfaces of a magnetic tape. This method is unsatisfactory, because thecleaning of the flat portion of the backcoat layer is insufficient, andalso the effect of cleaning the interiors of servo dots formed as pitsby laser beams is poor. The above cleaning treatment in combination witha blade treatment is also possible. However, a strong blade treatmentmay damage the backcoat layer, since the backcoat layer has a lowerstrength than the magnetic layer. On the contrary, if a weak bladingtreatment is made on the backcoat layer, the burnt residues thereoncannot be removed. Thus, this method is unsuitable for large-scaleproduction, because selection of the conditions for the cleaning isdifficult. Still worse, this method has substantially no effect ofcleaning the interiors of the servo dots formed as the pits.

The present invention has been completed to solve the foregoing problemsof the prior art.

SUMMARY OF THE INVENTION

The present inventors have intensively researched a magnetic tape onwhich optical servo signals having a high S/N ratio (signal to noise)can be recorded. As a result, they have discovered that the ratio of S/Nis increased by setting an average of the reflectance on the flatportion of a backcoat layer at 8.5% or higher, and also by decreasingthe rate of fluctuation of the reflectance on the flat portion dependingon a position of the magnetic tape (a site on the magnetic tape), whichis defined by the following equation, to 10% or lower:

[Maximum of absolute value of (Reflectance−Average ofreflectance)]×100/(Average of reflectance)

According to the first aspect, the present invention relates to amagnetic tape comprising a nonmagnetic support; a magnetic layer whichis formed on one surface of the nonmagnetic support; and a backcoatlayer which contains a binder and nonmagnetic powder containing carbonblack as one component and which is formed on the other surface of thenonmagnetic support, having pits for optical servo formed thereon,wherein the average of the reflectance on the flat portion of thebackcoat layer is 8.5% or higher, and wherein the maximum rate offluctuation of the reflectance on the flat portion depending on aposition of the magnetic tape, determined by the following equation, is10% or lower.

[Maximum of absolute value of (Reflectance−Average ofreflectance)]×100/(Average of reflectance)

To set the average of the reflectance on the flat portion of thebackcoat layer at 8.5% or higher, and also to lower the fluctuation ofthe reflectance on the flat portion depending on a site of the magnetictape to 10% or lower, the content of the nonmagnetic powder in thebackcoat layer:

(Weight of nonmagnetic powder)×100/(Weight of nonmagnetic powder+Weightof binder)

is controlled to 50 wt. % or more; the surface roughness Ra of the flatportion of the backcoat layer, measured with an atomic force microscope(AFM), is controlled to 30 nm or less; and the half width of thefluctuation of the surface roughness Ra depending on a site of themagnetic tape is controlled to 5 nm or less.

If the ratio of carbon black in the nonmagnetic powder is increased to80 wt. % or more, it becomes easy to form the pits for optical servo(i.e., servo holes) by irradiation with laser beams. The addition of 20wt. % or less of iron oxide (e.g., red iron oxide) in combination withcarbon black is effective to improve the strength of the backcoat layer.

The present inventors also have carefully researched the solution of theabove problem of a disorder in the winding of a magnetic tape having atotal thickness as thin as 6 μm or less. As a result, the inventors havefound out that the disorder in the winding of the tape can be preventedby setting the value of H/T at 1/50 or less, preferably 1/100 or less,wherein T is the total thickness of the magnetic tape, and H is theaverage height of 100 raised portions around the peripheries of the pitsof the backcoat layer (the peripheral portions of the pits for opticalservo).

Another object of the present invention is to provide a method and anapparatus for efficiently removing the burnt residue (powder, etc.)which form when pits for optical servo are formed on the backcoat layerof a magnetic tape by irradiation with laser beams and which adhere tothe interiors of the pits and their peripheries on the backcoat layer,and also to provide a magnetic tape having a low error rate.

As a result of the researches of a method for efficiently removing suchburnt residues, the following methods are found to be effective: (1)cleaning by using CO₂, and (2) cleaning by using a raised fabric or thelike. The method (1) using CO₂ requires a relatively large-scaleapparatus, while it is relatively low in running cost, since onlyconsumable is CO₂. On the other hand, the method (2) using a raisedfabric requires a relatively simple apparatus, although consuming raisedfabrics.

Therefore, according to the second aspect, the present invention relatesto a method for cleaning a magnetic tape which comprises a nonmagneticsupport, a magnetic layer formed on one surface of the nonmagneticsupport, and a backcoat layer which contains nonmagnetic powder and abinder and which is formed on the other surface of the nonmagneticsupport, having pits for optical servo, formed thereon by irradiationwith laser beams, which method comprises the step of spraying solid CO₂onto the surface of the backcoat layer, thereby removing burnt residueswhich forms after the laser irradiation and adheres to the pits foroptical servo and their peripheries, so as to clean the backcoat layer.

According to the third aspect, the present invention relates to anapparatus for forming and cleaning optical servo tracks of a magnetictape, which apparatus comprises a tape-feeding mechanism for feeding areeled magnetic tape in a predetermined direction; a unit for formingoptical servo tracks by forming pits on the surface of the backcoatlayer of the fed magnetic tape by irradiation with laser beams; a unitfor cleaning the surface of the backcoat layer after the formation ofthe pits; and a mechanism for winding the magnetic tape after cleaning.The cleaning unit comprises a section for spraying solid CO₂ onto thepits for optical servo and their peripheries on the backcoat layer; asection for sucking the burnt residues which are blown off by the solidCO₂ and adhere to the pits and their peripheries; and a section forwiping the surface of the backcoat layer after the suction of the burntresidues.

According to the fourth aspect, the present invention relates to amethod for cleaning a magnetic tape which comprises a nonmagneticsupport, a magnetic layer formed on one surface of the nonmagneticsupport, and a backcoat layer which contains nonmagnetic powder and abinder and which is formed on the other surface of the nonmagneticsupport, having pits for optical servo formed thereon by irradiationwith laser beams, which method comprises the steps of allowing a raisedfabric or a woven or nonwoven fabric having raising fibers thereon, tocontact with the surface of the backcoat layer having the pits thereon,and removing the burnt residues adhered to the pits and theirperipheries.

According to the fifth aspect, the present invention relates to anapparatus for forming and cleaning optical servo tracks of a magnetictape, which apparatus comprises a tape-feeding mechanism for feeding areeled magnetic tape in a predetermined direction; a unit for formingoptical servo tracks by forming pits on the surface of the backcoatlayer of the fed magnetic tape by irradiation with laser beams; a unitfor cleaning the surface of the backcoat layer after the formation ofthe pits; and a winding means for winding the magnetic tape aftercleaning. The cleaning unit comprises a section for allowing a raisedfabric or a woven or nonwoven fabric having raising fibers thereon tocontact with the surface of the backcoat layer so as to clean the same,and a section for wiping and removing unwanted particles adhered to thesurface of the backcoat layer.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic diagram illustrating the spraying of solid CO₂onto the surface of the backcoat layer of a magnetic tape.

FIG. 2 a schematic diagram illustrating an angle at which a nozzle forspraying CO₂ is set.

FIG. 3 is a perspective view of the essential portion of an apparatusfor forming and cleaning optical servo tracks, illustrating aCO₂-spraying section and a sucking section.

FIG. 4 is a schematic diagram illustrating an example of a sucking means(a suction nozzle).

FIG. 5 is a schematic diagram illustrating another example of a suckingmeans (a suction nozzle).

FIG. 6 is a perspective view of a magnetic tape, illustrating an exampleof servo patterns formed on the surface of the backcoat layer.

FIG. 7 is a schematic diagram illustrating the whole structure of anapparatus for forming and cleaning optical servo tracks, used inExamples of the present invention.

FIG. 8 is a perspective view of a contact-removing section and itsperiphery in an apparatus for forming and cleaning optical servo tracks,used in Examples of the present invention.

FIG. 9 is a schematic diagram illustration the construction of a wholeof another apparatus for forming and cleaning optical servo tracks, usedin Examples of the present invention.

BEST EMBODIMENTS FOR CARRYING OUT INVENTION

Firstly the cleaning method (1) using CO₂ is described.

A magnetic tape is caused to run in the lengthwise direction, while thebackcoat layer thereof is being irradiated with laser beams to form pitsfor optical servo on the backcoat layer. After this step, solid CO₂ issprayed onto the surface of the backcoat layer having the pits formedthereon. Thereby, the burnt residues adhered to the interiors of thepits and their peripheries are removed only by causing the magnetic tapeto run once.

As shown in FIGS. 1 to 3, the magnetic tape (1) to be cleaned is run ata high speed, for example, about 10 m/sec., while solid CO₂ (which hasbeen in a liquid phase when sprayed, and is changed to a solid stateimmediately after sprayed) is sprayed onto the surface of the backcoatlayer (2), to efficiently remove the particles adhered to the surface ofthe backcoat layer (2). In FIGS. 1 to 3, numeral 3 refers to anonmagnetic support; 4, to a magnetic layer; 5, to a servo patternconsisting of a plurality of pits for optical servo; and 6, to a primerlayer.

Although not bound by any theory, the reason why the burnt residues canbe efficiently removed by spraying such solid CO₂ may be considered asfollows. Carbon dioxide (CO₂) sprayed onto the surface of the backcoatlayer is in a liquid state at a specific temperature or lower under aspecific pressure or higher. However, after the spraying, the pressurerapidly lowers, so that carbon dioxide is changed from a liquid state toa solid state to form dry ice fine particles. These dry ice particlesare sprayed from a spray nozzle (15) and then struck onto a part of thesurface of the backcoat layer (2) of the magnetic tape (1) to fly andspread over the peripheral area of such a part of the backcoat layer(the dry ice particles forms carbon dioxide gas in short time). The dryice particles adsorb the particles (mainly the burnt residues) adheredto the surface of the backcoat layer when struck thereto. Thus, theburnt residues on the surface of the backcoat layer are separated andremoved. As shown in FIG. 3, a sucking means such as a suction nozzle(16) sucks the gas in the CO₂-sprayed region or its periphery in thisstep, so that the burnt residues can be more efficiently removed.

In the mode shown in FIG. 3, the suction nozzle (16) having a suctionport (16 a) with a width larger than the tape width is arranged abovethe backcoat layer. The sucking means is not limited to this type, andit may be such a sucking means (16) as shown in FIG. 4, which has asuction port (16 a) surrounding the surface and both edge portions ofthe backcoat layer (2) of the magnetic tape (1) (both end portions ofthe magnetic tape (1) along the tape lengthwise direction), viewed froma direction reverse to the tape-running direction. Alternatively, it maybe such a sucking means (16) as shown in FIG. 5, which has a suctionport (16 a) enclosing a whole of a tape, viewed from a direction reverseto the tape-running direction. Further, although not shown herein, itmay be such a sucking means that encloses a whole of the CO₂-sprayedregion including a CO₂-spraying nozzle (15), but is arranged so as notto hinder the running of a magnetic tape.

FIG. 6 shows an example of a pattern (a servo pattern) for arraying pitsfor optical servo, which is formed by irradiation with laser beams. Theservo pattern (5) shown in FIG. 6 is formed on a magnetic tape (1)having a width of 12.64 mm (½ in.). In this example, four bands (5 a)extending along the tape lengthwise direction are formed on the tape inthe widthwise direction. The width of one band (5 a) is about 0.4 mm.Microscopically, each one of the bands (5 a) is composed of one row ofpits for optical servo, arrayed along the tape lengthwise direction, anda plurality of such rows of the pits are arranged at intervals in thetape widthwise direction. The burnt particles resulting from the laserirradiation most abundantly adhere to the interiors of the pits withinthe servo pattern. Therefore, the most efficient spray nozzle (15) has aplurality of spray orifices (15 a) which correspond to the bands (5 a),one to one, as shown in FIG. 3. The spray nozzle (15) shown in FIG. 3has four spray orifices (15 a) corresponding to a pattern of four bands.The solid CO₂ (which has been in a liquid phase when sprayed, asdescribed above) is uniformly sprayed from the spray orifices (15 a), sothat the pits forming the servo pattern (5) and their peripheries aresurely cleaned.

In another mode, solid CO₂ is sprayed from a CO₂-spraying nozzleinclined at a certain angle, toward a direction reverse to a magnetictape which is running at a high speed (e.g., 10 m/sec.). In moreparticular, as shown in FIGS. 2, 3 and 7, the spray nozzle (15)inclined, for example, at an angle of 30 to 90°, preferably 30 to 60°relative to the surface of the backcoat layer (2), is arranged in thefront of a portion of the surface of the backcoat layer onto which thesolid CO₂ is sprayed (i.e., solid CO₂-receiving portion), when viewedfrom the magnetic tape-running direction A. The solid CO₂ is sprayedtherefrom in a direction reverse to the tape-running direction A, and isstruck to the CO₂-receiving portion. Thereby, the burnt residues adheredto the pits and their peripheries on the surface of the backcoat layerare blown off Since this method makes it possible to increase therelative CO₂-spraying speed while the flow of CO₂ onto the pits foroptical servo is being maintained, the cleaning effect can be improved.

To efficiently form a servo pattern, such an apparatus as describedbelow is effectively used. That is, the apparatus can form pits foroptical servo on the surface of the backcoat layer by irradiation withlaser beams, while running several thousands meters of a reeled magnetictape, and then, the apparatus cleans and wipes the surface of thebackcoat layer, followed by rewinding the magnetic tape in good order.In the present invention, as the apparatus used is such an apparatusthat forms and cleans optical servo tracks on a magnetic tape as shownin FIG. 7. This apparatus comprises a tape-feeding mechanism (11) forfeeding a reeled magnetic tape (1) in a predetermined direction; anoptical servo track-forming unit (12) for forming pits for optical servoon the surface of the backcoat layer of the fed magnetic tape (1) byirradiation with laser beams; a cleaning unit (13) for cleaning thesurface of the backcoat layer after the formation of the pits; and atape-winding mechanism (14) for winding the magnetic tape (1) aftercleaning. The cleaning unit (13) comprises a CO₂-spraying sectionequipped with a spray nozzle (15) for spraying solid CO₂ onto the abovepits and their peripheries; a sucking section equipped with a suctionnozzle (16) for sucking burnt residues which are blown off by thespraying of the solid CO₂ and adhered to the pits and their peripheries;and a wiping section (17) for wiping the surfaces of the backcoat layerand the magnetic layer, for example, by means of tissue after thesuction of the burnt residues.

In the above apparatus, a tension loss occurs in each of the opticalservo track-forming unit (12), and the CO₂-spraying section and thewiping section in the cleaning unit (13), so that the magnetic tape maybe held under a tension which exceeds an optimal tension (e.g., 70 to200 g) to the tape. Accordingly, it is preferable to provide tensioncontrolling means for individually controlling the tension of themagnetic tape in each of the unit and the sections. As will be describedlater in the part of Examples, the first to third suction rolls (22 to24) are provided so as not to transmit the tension, while the values oftension detectors (27 and 28) which are provided in the respective unitsare feedback-controlled via a servo motor for rotating the suction rolls(22 to 24), so that the magnetic tape (1) is run under an optimaltension maintained.

Next, the cleaning method (2) using a raised fabric or the like isdescribed.

A method for efficiently removing burnt residues, which are formed byirradiation with laser beams and adhered to the interiors of pits foroptical servo and their peripheries, with a relatively simple apparatushas been researched. As a result, a method which comprises a step ofallowing a raised fabric or a woven or nonwoven fabric having raisingfibers thereon (preferably velvet) to contact with a magnetic taperunning in the lengthwise direction is found to be very effective toremove the burnt residues only by running the magnetic tape once.According to the present invention, a raised fabric or a woven ornonwoven fabric having raising fibers thereon (preferably velvet) isallowed to contact with the surface of the backcoat layer of a magnetictape which is being run at a high speed, for example, about 10 m/sec. soas to clean the surface of the backcoat layer. Thereby, the burntresidues (powder, etc.) adhered to the interiors of the pits for opticalservo and their peripheries on the surface of the backcoat layer areefficiently removed.

To carry out the above method, an apparatus for forming and cleaningoptical servo tracks on a magnetic tape as shown in FIG. 9 may be usedin the present invention. The apparatus comprises a tape-feedingmechanism (11) for feeding a reeled magnetic tape (1) in a predetermineddirection; an optical servo track-forming unit (12) for forming pits foroptical servo on the surface of the backcoat layer of the fed magnetictape (1) by irradiation with laser beams; a cleaning unit (13) forcleaning the surface of the backcoat layer after the formation of thepits; and a tape-winding mechanism (14) for winding the magnetic tape(1) after cleaning. The cleaning unit (13) comprises a contact-removingsection (15 b) for allowing a raised fabric or a woven or nonwovenfabric having raising fibers thereon, to contact with the surface of thebackcoat layer so as to clean the same; and a wiping section (17) forwiping and removing unwanted particles adhered to the surface of thebackcoat layer. This apparatus has high productivity, because theapparatus can perform the formation of pits for optical servo on thebackcoat layer of a magnetic tape and the cleaning thereof by removingthe burnt residues, on one line. In this case, tension-controlling meansare separately provided in each of the optical servo track-forming unit,and the contact-removing section and the wiping section in the cleaningunit, so that the tension of the magnetic tape can be controlled in eachof the unit and the sections by such tension-controlling means. By thisarrangement, the productivity is improved.

The reason why the burnt residues in the pits and their peripheries onthe surface of the backcoat layer are efficiently removed may beconsidered as follows. The raising fibers of the woven or nonwoven clothhave appropriate lengths and rigidity, and thus, such raising fibersenter the pits and efficiently rake out the burnt residues from thepits.

The diameter of a single fiber out of the raising fibers is preferably0.5 to 10 μm, more preferably 1 to 8 μm, particularly 2 to 6 μm. If thediameter of such a single fiber is smaller than 0.5 μm, the rigidity(toughness) of the fiber is insufficient, and thus, such a fiber hardlyrakes out the burnt residues. On the other hand, if the diameter of asingle fiber exceeds 10 μm, such a fiber is hard to enter a pit.

The length of the single fiber is preferably 0.5 to 5 mm, morepreferably 1 to 4 mm, particularly 1 to 3 mm. If the length of thesingle fiber is shorter than 0.5 mm, such a fiber hardly enters a pit.On the other hand, if the length of the single fiber exceeds 5 mm, therigidity (toughness) of the fiber becomes poor, and thus hardly rakesout the burnt residue. It is also effective to split the tip end portionof a thick single fiber for use, so as to obtain a raking effect whilemaintaining the rigidity of the fiber.

The raising fibers are of at least one selected from natural fibers suchas cotton and hemp, and synthesized fibers such as rayon and polyester.The fibers may be of a single kind or of a blended kind. The fibers maybe of a single fiber or of a twisted yarn of at least two fibers.

Preferably, a material for such raising fibers contains at least cotton,since cotton has a proper rigidity (toughness) and thickness. Forexample, a blended fiber containing 30 to 70% of cotton and 70 to 30% ofrayon can be used.

As already described with reference to FIG. 6, the fine particles formedas a result of the laser beam irradiation most abundantly adhere to theinteriors of the pits of the servo pattern. As shown in FIG. 8, theraised fabric or the woven or nonwoven fabric (32) having raising fibersthereon may be wrapped around a rotary drum (31), and such a fabric maybe replaced for each one reel of a magnetic tape (1) having a continuouslength of several thousands meters. Otherwise, such a fabric may becontinuously fed to the drum. Herein, the former type is employed,because the apparatus to be used is more simple than the latter type.

As shown in FIG. 8, the wrapped drum (30) (the rotary drum (31) wrappedat its outer circumference with the raised fabric (32)) is allowed tocontact with the surface of the backcoat layer (2) of a magnetic tape(1) which is running at a high speed, for example, 10 m/sec., at acontact angle of 90 to 140°, while the wrapped drum (30) is beingrotated at a certain velocity [30 to 50 rps (1,800 to 3,000 rpm)] in adirection reverse to the tape-running direction. The tension applied tothe magnetic tape on the side of the inlet is set at 50 to 100 g, whilethe tension applied to the magnetic tape on the side of the outlet isset at 170 to 260 g, so that the tension of the magnetic tape isadjusted to 1.7 to 2.5 N. Thereby, the burnt residue-removing effect isimproved.

If the contact angle is less than 90°, it is needed to reduce thetape-feeding speed, so that longer time is required to remove the burntresidues. In case where the treating time is short, the burnt residuesdrop from the pits of the backcoat layer and again adhere to themagnetic layer and the flat portion of the backcoat layer whilerecording/reproducing is repeatedly performed on or from the magnetictape. As a result, the error rate increases, and the ratio of SN ofservo signals decreases. If the contact angle exceeds 140°, thecomponents of the apparatus are arranged in a cramped state. In general,the contact angle is preferably at 90 to 120°.

The rotating velocity of the wrapped drum is preferably from 188.4 to314 radian/sec. (1,800 to 3,000 rpm). If the rotating velocity is lowerthan 188.4 radian/sec. (1,800 rpm), it is needed to reduce thetape-feeding speed, so that longer time is required to remove the burntresidues. If the rotating velocity exceeds 314 radian/sec. (3,000 rpm),an expensive motor is needed. Alternatively, two or more wrapped drumsmay be arranged. However, in this case, the dimensions of the apparatusbecome larger.

To efficiently form a servo pattern, a magnetic tape with a continuouslength of several thousands meters or longer wound onto a reel is beingrun, while pits for optical servo are being formed on the surface of thebackcoat layer by irradiation with laser beams; the backcoat layer issubjected to a cleaning treatment and a wiping treatment; and then, themagnetic tape is again wound in good order. The apparatus to be used inthe above steps may be an optical servo track-forming and -cleaningapparatus as shown in FIG. 9, which comprises a tape-feeding mechanism(11) for feeding a reeled magnetic tape (1) in a predetermineddirection; an optical servo track-forming unit (12) for forming pits foroptical servo on the surface of the backcoat layer of the fed magnetictape (1) by irradiation with laser beams; a cleaning unit (13) forcleaning the surface of the backcoat layer after the formation of thepits; and a tape-winding mechanism (14) for winding the magnetic tape(1) after cleaning. The cleaning unit (13) comprises a contact-removingsection (15 b) for allowing a raised fabric or a woven or nonwovenfabric having raising fibers thereon, to contact with the surface of thebackcoat layer so as to clean the same; and a wiping section (17) forwiping and removing unwanted particles adhered to the surface of thebackcoat layer, using, for example, a tissue. However, in the apparatusof this type, a tension loss occurs in each of the optical servotrack-forming unit (12), and the contact-removing section (15 b) and thewiping section (17) in the cleaning unit (13), so that the tensionapplied to the tape sometimes exceeds an optimal tension to the tape(e.g., 70 to 200 g). To overcome this problem, it is preferable toprovide tension-controlling means in each of the unit and the sectionsso as to separately control the tension of the magnetic tape in eachunit or section. This is described in more detail. As will be describedlater in the part of Examples, the first to third suction rolls (22 to24) are provided so as not to transmit the tension, and the values oftension detectors (27 and 28) provided in the respective units arefeedback-controlled via a servo motor for rotating the suction rolls (22to 24), so that the magnetic tape (1) can be run under an optimaltension maintained.

Hereinafter, the respective elements of a magnetic recording medium aredescribed.

<Nonmagnetic Support>

The thickness of a nonmagnetic support is preferably 7.0 μm or less,more preferably from 2.0 to 7.0 μm. When the thickness of thenonmagnetic support is less than 2 μm, it is difficult to form a film.Furthermore, the strength of the resultant magnetic tape decreases. Whenthe thickness of the nonmagnetic support exceeds 7.0 μm, the totalthickness of the magnetic tape increases so that the recording capacityper one reel of the magnetic tape decreases.

The Young's modulus of the nonmagnetic support in the lengthwisedirection depends on the thickness of the support, and is usually atleast 4.9 GPa (500 kg/mm²). When the thickness of the support is 5.0 μmor less, the Young's modulus is preferable at least 9.8 GPa (1,000kg/mm²). If the Young's modulus of the nonmagnetic support is lower than4.9 GPa (500 kg/mm²), the strength of the magnetic tape becomes poor, orthe running of the magnetic tape becomes unstable.

The ratio of Young's modulus MD in the lengthwise direction to Young'smodulus TD in the widthwise direction (MD/TD) of the nonmagnetic supportis preferably from 1.0 to 1.8, more preferably from 1.1 to 1.7. When theratio of MD/TD is within this range, the head touch is improved.

Examples of such a nonmagnetic support include a polyethyleneterephthalate film, a polyethylene naphthalate film, an aromaticpolyamide film, an aromatic polyimide film, etc.

<Primer Layer>

A primer layer may be formed between a nonmagnetic support and amagnetic layer. The thickness of the primer layer is preferably from 0.3to 3.0 μm, more preferably from 0.3 to 2.5 μm, particularly 0.3 to 2.0μm. When the thickness of the primer layer is less than 0.3 μm, thedurability of the magnetic tape may become poor. When the thickness ofthe primer layer exceeds 3.0 μm, the effect to improve the durability ofthe magnetic tape is saturated, and the total thickness of the magnetictape increases. Accordingly, the length of the tape per one reeldecreases, so that the recording capacity decreases.

The primer layer may contain carbon black (CB) to improve theconductivity, and contain nonmagnetic particles to control the viscosityof a paint and the stiffness of the magnetic tape. Examples of thenonmagnetic particles to be contained in the primer layer includetitanium oxide, iron oxide, alumina, etc. The addition of iron oxidealone, or a mixture of iron oxide and alumina is preferable.

The surface roughness of the magnetic layer, which is formed on theprimer layer by a wet-on-wet method, can be reduced, when the primerlayer contains 15 to 35 wt. % of carbon black having a particle size of10 to 100 nm, 35 to 83 wt. % of nonmagnetic iron oxide having a majoraxis length of 0.05 to 0.20 μm and a minor axis length of 5 to 200 nm,and optionally 0 to 20 wt. % of alumina having a particle size of 10 to100 nm, based on the weight of the total inorganic particles containedin the primer layer.

The nonmagnetic iron oxide particles may be of a needle shape, orparticulate or random shape. When particulate or random nonmagnetic ironoxide is used, its particle size is preferably from 5 to 200 nm.

The present invention does not avoid the addition of large size carbonblack (CB) having a particle size of 100 nm or more, provided that thesurface smoothness is not impaired. In this case, preferably, the sum ofthe small size carbon black (CB) and the large size carbon black (CB) iswithin the above range.

Examples of carbon black (CB) to be added to the primer layer areacetylene black, furnace black, thermal black, etc. Such carbon blackusually has a particle size of 5 to 200 nm, preferably 10 to 100 nm.When the particle size of carbon black is less than 10 nm, it may bedifficult to disperse the carbon black particles, since carbon black hasa structure. When the particle size of carbon black exceeds 100 nm, thesurface smoothness of the primer layer degrades.

The amount of carbon black to be contained in the primer layer variesdepending on the particle size of carbon black, and it is preferablyfrom 15 to 35 wt. %. When the amount of carbon black is less than 15 wt.%, the conductivity may not be sufficiently improved. When the amount ofcarbon black exceeds 35 wt. %, the effects of the addition of carbonblack may saturate. More preferably, carbon black having a particle sizeof 15 to 80 nm is used in an amount of 15 to 35 wt. %, and particularly,carbon black having a particle size of 20 to 50 nm is used in an amountof 20 to 30 wt. %. When carbon black having the above particle size isused in the above-defined amount, the electrical resistance isdecreased, and the feeding irregularity is lessened.

The nonmagnetic iron oxide to be added to the primer layer preferablyhas a major axis length of 0.05 to 0.20 μm and a minor axis length(particle diameter) of 5 to 200 nm in the case of the needle-shapeparticles, or it has a particle size of 5 to 200 nm, preferably 5 to 150nm, more preferably 5 to 100 nm, in the case of the particulate orrandom shape particles. In particular, the needle-shape iron oxideparticles are preferable, since the orientation of the magnetic layercan be improved. The amount of the nonmagnetic iron oxide to be added tothe primer layer is preferably from 35 to 83 wt. %, more preferably from40 to 80 wt. %. When the particle size of the nonmagnetic iron oxide(the minor axis length in case of the needle shape particle) is lessthan 5 nm, the iron oxide particles may not be uniformly dispersed. Whenthe particle size exceeds 200 nm, the unevenness of the interfacebetween the primer layer and the magnetic layer may increase. When theamount of the nonmagnetic iron oxide is less than 35 wt. %, the effectto improve the strength of the primer layer is poor. When the amount ofthe iron oxide exceeds 83 wt. %, the strength of the primer layer mayrather decrease.

The primer layer may contain alumina in addition to iron oxide. Theparticle size of alumina is preferably from 10 to 100 nm, morepreferably from 20 to 100 nm, particularly from 30 to 100 nm. When theparticle size of alumina is less than 10 nm, the alumina particles maynot be uniformly dispersed. When the particle size of alumina exceeds100 nm, the unevenness of the interface between the primer layer and themagnetic layer tends to increase. The amount of alumina to be added tothe primer layer is usually from 0 to 20 wt. %, preferably from 2 to 10wt. %.

<Lubricant>

A coating layer comprising the primer layer and the magnetic layer maycontain a lubricant having a different function. The coefficient ofdynamic friction of the magnetic tape against the guide of the feedingsystem or the like can be decreased, for example, when the primer layercontains 0.5 to 4.0 wt. % of a higher fatty acid and 0.2 to 3.0 wt. % ofa higher fatty acid ester, based on the weight of the entire powdercomponents in the primer layer. When the amount of the higher fatty acidis less than 0.5 wt. %, the effect to decrease the coefficient ofdynamic friction is insufficient. When the amount of the higher fattyacid exceeds 4.0 wt. %, the primer layer may be plasticized and thus thetoughness of the primer layer may be lost. When the amount of the higherfatty acid ester is less than 0.5 wt. %, the effect to decrease thecoefficient of friction is insufficient. When the amount of the higherfatty acid ester exceeds 3.0 wt. %, the amount of the higher fatty acidester which migrates to the magnetic layer may become too large, so thatthe magnetic tape may stick to the guide or the like of the feedingsystem.

As the fatty acid, higher fatty acids such as lauric acid, myristicacid, palmitic acid, stearic acid, behenic acid, oleic acid, linoleicacid, etc. can be used. As the fatty acid ester, butyl stearate, octylstearate, amyl stearate, isooctyl stearate, octyl myristate, butoxyethylstearate, anhydrous sorbitan monostearate, anhydrous sorbitandistearate, anhydrous sorbitan tristearate, etc. can be used.

The coefficient of dynamic friction of the magnetic tape against theguide roller of the feeding system or the slider of the MR head can bedecreased, when the magnetic layer contains 0.2 to 3.0 wt. % of a fattyacid amide and 0.2 to 3.0 wt. % of a higher fatty acid ester, based onthe weight of the ferromagnetic powder. When the amount of the fattyacid amide is less than 0.2 wt. %, the coefficient of dynamic frictionbetween the head slider and the magnetic layer tends to increase. Whenthe amount of the fatty acid amide exceeds 3.0 wt. %, the fatty acidamide bleeds out and causes a defect such as dropout.

When the amount of the higher fatty acid ester is less than 0.2 wt. %,the coefficient of dynamic friction is hardly decreased. When the amountof the higher fatty acid ester exceeds 3.0 wt. %, the magnetic tapesticks to the guide of the feeding system.

As the fatty acid amide, the amides of the above higher fatty acids suchas palmitic acid, stearic acid and the like can be used.

The intermigration between the lubricant of the magnetic layer and thelubricant of the primer layer may be allowed.

The coefficient of dynamic friction (μ_(msL)) between the magnetic layerand the slider of the MR head is preferably 0.30 or less, morepreferably 0.25 or less. When this coefficient of dynamic frictionexceeds 0.30, the spacing loss tends to arise due to the contaminationon the slider. The coefficient of dynamic friction of less than 0.10 ishardly realized.

The coefficient of dynamic friction (μ_(msus)) between the magneticlayer and SUS is preferably from 0.10 to 0.25, more preferably from 0.12to 0.20. When this coefficient of dynamic friction is less than 0.10,the tape is so slidable on the guide portion that the tape cannot bestably run. When this coefficient of dynamic friction exceeds 0.25, theguide rollers may easily be contaminated.

The ratio of [(μ_(mSL))/(μ_(mSUS))] is preferably from 0.7 to 1.3, morepreferably from 0.8 to 1.2. In this preferred range, dislocation from atrack (off-track) because of the tape-meandering becomes smaller.

<Magnetic Layer>

The thickness of a magnetic layer is usually 0.3 μm or less, preferablyfrom 0.01 to 0.3 μm, more preferably from 0.01 to 0.25 μm, particularlyfrom 0.01 to 0.10 μm.

When the thickness of the magnetic layer is less than 0.01 μm, it isdifficult to form an uniform magnetic layer. When the thickness of themagnetic layer exceeds 0.3 μm, the reproducing output may decrease dueto the thickness loss, or the product of the residual magnetic fluxdensity and the thickness becomes too large, so that the reproducingoutput tends to be skewed due to the saturation of the MR head.

The coercive force of the magnetic layer is preferably from 120 to 320kA/m, more preferably from 140 to 320 kA/m. When the coercive force ofthe magnetic layer is less than 120 kA/m, less recording wavelengthcauses output decrease due to the demagnetizing field demagnetization,when the recording wavelength is shortened. When the coercive forceexceeds 320 kA/m, the recording with the magnetic head may becomedifficult.

The product of the residual magnetic flux density in the lengthwisedirection and the thickness is preferably from 0.0018 to 0.06 μTm, morepreferably from 0.0036 to 0.050 μTm. When this product is less than0.0018 μTm, the reproducing output with the MR head may be low. Whenthis product exceeds 0.06 μm, the reproducing output with the MR headtends to be skewed.

The contact between the magnetic tape and the MR head can be improved,and the reproducing output with the MR head increases, under thefollowing conditions: the average surface roughness Ra of the magneticlayer is from 3.2 nm to 1.0 nm; and the value of (P₁-P₀) is from 30 nmto 10 nm, and the value of (P₁-P₂₀), 5 nm or less, wherein P is thecenter value of the unevenness of the magnetic layer; P₁ is the heightof the highest projection of the magnetic layer; and P₂₀ is the heightof the 20th highest projection.

As the magnetic powder to be added to the magnetic layer, ferromagneticiron metal powder or hexagonal barium ferrite powder may be used. Thecoercive force of the ferromagnetic iron metal powder or hexagonalbarium ferrite powder is preferably from 120 to 320 kA/m. The saturationmagnetization is preferably from 120 to 200 A·m²/kg (120 to 200 emu/g),more preferably from 130 to 180 A·m²/kg (130 to 180 emu/g) in case ofthe ferromagnetic iron metal powder. It is preferably from 50 to 70A·m²/kg (50 to 70 emu/g) in case of the hexagonal barium ferrite powder.

The magnetic characteristics of the magnetic layer and the ferromagneticpowder are measured with a vibration sample magnetometer in an externalmagnetic field of 1.28 MA/m (16 kOe).

An average major axis length of the ferromagnetic iron metal powder ispreferably from 0.03 to 0.2 μm, more preferably from 0.03 to 0.18 μm,particularly from 0.03 to 0.10 μm. When the average major axis length isless than 0.03 μm, the dispersion of the powder in the paint isdifficult since the agglomeration force of the magnetic powderincreases. When the average major axis length exceeds 0.2 μm, thecoercive force decreases, or the particle noise due to the particle sizeincreases. For the same reason, the plate size of the hexagonal bariumferrite powder is preferably from 5 to 200 nm, more preferably 10 to 100nm, particularly 10 to 50 nm.

The average major axis length and the particle size are obtained byactually measuring the particle sizes on a photograph taken with ascanning electron microscope (SEM) and averaging the measured values of100 particles.

The BET specific surface area of the ferromagnetic iron metal powder ispreferably at least 35 m²/g, more preferably at least 40 m²/g,particularly at least 50 m²/g as the best. The BET specific surface areaof the hexagonal barium ferrite powder is preferably 1 to 100 m²/g.

A binder to be contained in the primer layer or the magnetic layer maybe a combination of a polyurethane resin and at least one resin selectedfrom the group consisting of a vinyl chloride resin, a vinylchloride-vinyl acetate copolymer resin, a vinyl chloride-vinyl alcoholcopolymer resin, a vinyl chloride-vinyl acetate-vinyl alcohol copolymerresin, a vinyl chloride-vinyl acetate-maleic anhydride copolymer resin,a vinyl chloride-hydroxyl group-containing alkyl acrylate copolymerresin, nitrocellulose, and the like. Among them, a mixture of a vinylchloride-hydroxyl group-containing alkyl acrylate copolymer resin and apolyurethane resin is preferably used. Examples of the polyurethaneresin include polyesterpolyurethane, polyetherpolyurethane,polyetherpolyesterpolyurethane, polycarbonatepolyurethane,polyestrepolycarbonatepolyurethane, etc.

Preferably, a binder resin such as an urethane resin formed from apolymer having a functional group such as COOH, SO₃M, OSO₂M, P═O(OM)₃,O—PαO(OM)₂ [wherein M is a hydrogen atom, an alkali metal ion or anamine salt], OH, NR¹R², N⁺R³R⁴R⁵ [wherein R¹, R², R³, R⁴ and R⁵ are eacha hydrogen atom or a hydrocarbon group], or an epoxy group is used. Thereason why such a binder is used is that the dispersibility of themagnetic powder or the like is improved. When two or more resins areused in combination, it is preferable that the polarities of thefunctional groups of the resins are the same. In particular, thecombination of resins both having —SO₃M groups is preferable.

The binder is used in an amount of 7 to 50 parts by weight, preferablyfrom 10 to 35 parts by weight, based on 100 parts by weight of theferromagnetic powder. In particular, the combination of 5 to 30 parts byweight of a vinyl chloride-based resin and 2 to 20 parts by weight ofthe polyurethane resin is best.

It is preferable to use a thermally curable crosslinking agent, whichbonds with the functional groups in the binder to crosslink the binder.As the crosslinking agent, the following are preferably used: tolylenediisocyanate, hexamethylene diisocyanate and isophorone diisocyanate;reaction products of these isocyanates with compounds having pluralhydroxyl groups such as trimethylolpropane; condensation products ofthese isocyanates, and the like.

The crosslinking agent is used in an amount of 10 to 50 parts by weight,preferably 10 to 35 parts by weight, based on 100 parts by weight of thebinder. When the amount of the crosslinking agent to be contained in themagnetic layer is about 50% (for example, 30 to 60%) of that containedin the primer layer, the coefficient of dynamic friction of the magneticlayer against the slider of the MR head is preferably decreased. Whenthe amount of the crosslinking agent is less than 30%, the film strengthof the magnetic layer tends to decrease, while, when it exceeds 60%, theLRT treatment conditions (the conditions for the wiping treatment usingtissue) should be selected severely so as to decrease the coefficient ofdynamic friction against the slider, which leads to the increase ofcost.

The magnetic layer may contain conventional carbon black (CB) to improvethe conductivity and the surface lubricity. As carbon black, acetyleneblack, furnace black, thermal black, etc. may be used. Carbon blackhaving a particle size of 5 to 200 nm is generally used, and carbonblack having a particle size of 10 to 100 nm is preferable. When theparticle size of carbon black is less than 5 nm, the dispersion ofcarbon black particles is difficult. When the particle size of carbonblack exceeds 200 nm, a large amount of carbon black should be added. Ineither case, the surface of the magnetic layer becomes coarse and thusthe output tends to decrease.

The amount of carbon black is preferably from 0.2 to 5 wt. %, morepreferably from 0.5 to 4 wt. %, based on the weight of the ferromagneticpowder. When the amount of carbon black is less than 0.2 wt. %, theeffect of the addition of carbon black is insufficient. When the amountof carbon black exceeds 5 wt. %, the surface of the magnetic layer tendsto be rough.

<Backcoat Layer>

The thickness of a backcoat layer is preferably from 0.25 to 0.8 μm,more preferably from 0.4 to 0.8 μm, particularly from 0.4 to 0.6. Whenthe thickness of the backcoat layer is less than 0.25 μm, the conditionsfor forming pits for optical servo (the power of the laser, etc.) arehardly controlled. When the thickness of the backcoat layer exceeds 0.8μm, the total thickness of the magnetic tape increases, so that therecording capacity of the tape per one reel decreases.

The coefficient of dynamic friction (μ) between the backcoat layer andSUS is preferably from 0.10 to 0.30, more preferably from 0.10 to 0.25.When this coefficient of dynamic friction is less than 0.10, themagnetic tape becomes excessively slidable on the guide rollers, so thatthe running of the tape becomes unstable. When this coefficient ofdynamic friction exceeds 0.30, the guide rollers tend to becontaminated. The ratio of [(μ_(mSL))/(μ_(BSUS))] is preferably from 0.8to 1.5, more preferably from 0.9 to 1.4. Within this range, dislocationfrom a track (off-track) on the magnetic tape due to the tape-meanderingbecomes smaller.

The average of the reflectance on the flat portion of the backcoat layeris preferably 8.5% or more, more preferably 9.0% or more, particularly10% or more. When the average of the reflectance is less than 8.5%,servo signals (S) become low, which causes tracking failure. Thepractical upper limit of the average of the reflectance of a backcoatlayer is usually 15%. When the average of the reflectance of thebackcoat layer exceeds 15%, the durability generally may degrade in caseof an uniform backcoat layer. In case where a backcoat layer whoseaverage of the reflectance exceeds 15% is used, the average of thereflectance on the flat portion other than the portion where pits foroptical servo are formed is controlled below 15% so that the durabilityof the backcoat layer cannot degrade.

It is preferable that the average of the reflectance is controlled above8.5%, and also that the rate of fluctuation of reflectance on the flatportion depending on a site of the magnetic tape (a position on themagnetic tape), determined by the following equation, is controlledbelow 10%, preferably below 5%, more preferably below 3%, particularly0% as the best:

(Maximum of absolute value of fluctuation from average ofreflectance)×100/(Average of Reflectance)

When the rate of fluctuation exceeds 10%, the S/N of servo signalsdecreases, which induces a tracking error.

To evaluate the rate of fluctuation of reflectance depending on a siteof a magnetic tape, the fluctuation of reflectance per 40 mm length ofthe magnetic tape is investigated. This is because the fluctuation ofreflectance per 40 mm length of the magnetic tape is substantially equalto the fluctuation of reflectance over the entire length of the magnetictape.

To control the average of the reflectance on the flat portion above 8.5%and simultaneously to control the rate of fluctuation of reflectance onthe flat portion, depending on a site of the magnetic tape, below 10%,the content of the nonmagnetic powder in the backcoat layer, calculatedby the following equation, is controlled to 50 wt. % or more:

(Weight of nonmagnetic powder)×100/(Weight of nonmagnetic powder+Weightof binder),

and also the surface roughness Ra of the flat portion of the backcoatlayer, measured with an AFM, is controlled to 30 nm or less; and thehalf width of the fluctuation of the surface roughness Ra depending on asite of the magnetic tape is controlled to 5 nm or less. The surfaceroughness Ra of the flat portion is preferably 10 nm or more, morepreferably 20 nm or more. When the Ra is less than 10 nm, the durabilityof the magnetic tape tends to degrade. Therefore, it is necessary that,in case where a backcoat layer having a surface roughness Ra of lessthan 10 nm at the flat portion is used, the flat portion of the backcoatlayer, other than the pit-formed portion, should have a surfaceroughness Ra of 10 nm or more. In this regard, when the surfaceroughness Ra is measured at 100 points per an area of 40 μm×40 μm of amagnetic tape with the AFM, the results are substantially equal to theRa per a whole length of the magnetic tape and the fluctuation of Ra ofthe same.

As described above, the reflectance of the flat portion of the backcoatlayer increases, when the content of the nonmagnetic powder is 50 wt. %or more, and when the surface thereof is smooth. However, if the contentof the nonmagnetic powder in the backcoat layer is 60 wt. % or more, itis difficult to control the surface roughness Ra of the flat portion toless than 30 nm. Thus, when the surface roughness Ra of the flat portionis adjusted to 30 nm or less by making the calendering conditionssevere, the resultant backcoat layer tends to have a poor durability.For such reasons, the content of the nonmagnetic powder in the backcoatlayer is practically from 50 to 60 wt. %, preferably from 50 to 58 wt.%, more preferably from 50 to 56 wt. %, particularly from 53 to 56 wt.%.

Preferably, the proportion of carbon black in the nonmagnetic powder is80 wt. % or more, because the pits for optical servo can be easilyformed by irradiation with laser beams. More preferably, the proportionof carbon black is 85 wt. % or more. The addition of 20 wt. % or less ofiron oxide (e.g., red iron oxide) in combination with carbon black ismore preferable, because the strength of the backcoat layer is enhanced.

As carbon black (CB) to be contained in the backcoat layer, acetyleneblack, furnace black, thermal black, etc. can be used. In general,carbon black with a small particle size and carbon black with a largeparticle size are used. The particle size of small particle size carbonblack is usually from 5 to 200 nm, preferably from 10 to 100 nm. Whenthe particle size of small particle size carbon black is less than 10nm, it is difficult to disperse the carbon black particles. When theparticle size of small particle size carbon black exceeds 100 nm, alarge amount of carbon black should be added. In either case, thesurface roughness Ra of the backcoat layer is 30 nm or more, and thereflectance on the flat portion decreases.

When the large particle size black carbon having a particle size of 200to 400 nm is used in an amount of 5 to 15 wt. % of the whole amount ofcarbon black (total of the small particle size carbon black and thelarge particle size carbon black), the surface of the backcoat is notroughened and the effect to increase the tape-running performance isincreased. When the amount of the large particle size black carbon isless than 5 wt. %, the durability-improving effect is poor. When itexceeds 15 wt. %, the reflectance on the flat portion largelyfluctuates. The total amount of the small particle size carbon black andthe large particle size carbon black is preferably from 80 to 100 wt. %,more preferably from 85 to 100 wt. %, based on the weight of nonmagneticpowder. The surface roughness Ra of the backcoat layer, measured withthe AFM, is preferably 30 nm or less, and it is generally 10 nm or more,as described above.

To enhance the strength of the backcoat layer, it is preferable to add20 wt. % or less of inorganic additives such as iron oxide (e.g., ironoxide and alumina which are usually added to the backcoat layer) intotal, based on the weight of the inorganic powder. The addition amountof the inorganic additives is preferably from 2 to 20 wt. %, morepreferably 5 to 15 wt. %. When this amount is less than 2 wt. %, thestrength of the backcoat layer is not effectively improved. If itexceeds 20 wt. %, the formation of pits for optical servo by irradiationwith laser beams becomes difficult. In this regard, an oxide mainlycontaining iron oxide is preferably used, while iron oxide may be addedtogether with alumina at the same time. In the latter case, the additionamount of alumina is preferably 20 wt. % or less based on the weight ofthe iron oxide. When the addition amount of alumina exceeds 20 wt. %based on the weight of the iron oxide, it is needed to strictly selectthe conditions for cleaning the burnt residues. The particle size ofiron oxide (particles) is preferably from 0.05 to 0.4 μm, morepreferably from 0.07 to 0.35 μm. When the particle size of iron oxide isless than 0.05 μm, the strength of the backcoat layer is hardlyimproved. On the other hand, when it exceeds 0.4 μm, the reflectance onthe flat portion largely fluctuates.

The binder to be contained in the backcoat layer may comprise the sameresin as used in the magnetic layer and the primer layer. Among theseresins, the combination of a cellulose resin and a polyurethane resin ispreferably used so as to decrease the coefficient of friction and toimprove the tape-running performance.

The amount of the binder in the backcoat layer is usually from 40 to 150parts by weight, preferably from 50 to 120 parts by weight, morepreferably from 50 to 110 parts by weight, particularly from 50 to 100parts by weight, based on the total 100 parts by weight of carbon blackand the inorganic nonmagnetic powder in the backcoat layer. When theamount of the binder is less than 50 parts by weight, the strength ofthe backcoat layer is insufficient. When the amount of the binderexceeds 120 parts by weight, the coefficient of friction increases.Preferably, 30 to 70 parts by weight of a cellulose resin and 20 to 50parts by weight of a polyurethane resin are used. To cure the binder, acrosslinking agent such as a polyisocyanate compound is preferably used.

The crosslinking agent to be contained in the backcoat layer may be thesame as those used in the magnetic layer and the primer layer. Theamount of the crosslinking agent is usually from 10 to 50 parts byweight, preferably from 10 to 35 parts by weight, more preferably from10 to 30 parts by weight, based on 100 parts by weight of the binder.When the amount of the crosslinking agent is less than 10 parts byweight, the film strength of the backcoat layer tends to decrease. Whenthe amount of the crosslinking agent exceeds 50 parts by weight, thecoefficient of dynamic friction of the backcoat layer against SUSincreases.

<LRT (Lapping/Rotary/Tissue) Treatment>

The magnetic layer is subjected to a LRT treatment so as to optimize thesurface smoothness, the coefficient of dynamic friction against theslider of the MR head and the cylinder material, the surface roughnessand the surface shape. Thus, the running performance of the magnetictape and the reproducing output with the MR head are improved, and thespacing loss is reduced.

The respective steps of the LRT treatment are described below.

(1) Lapping:

An abrasive tape (lapping tape) is moved by a rotary roll at a constantrate (standard: 14.4 cm/min.) in a direction opposite to thetape-feeding direction (standard: 400 m/min.), and is allowed to contactwith the surface of the magnetic layer of the magnetic tape while beingpressed under the guide block. In this step, the magnetic layer ispolished while the unwinding tension of the magnetic tape and thetension of the lapping tape being maintained constant (standard: 100 gand 250 g, respectively).

The abrasive tape (lapping tape) (3) used in this step may be anabrasive tape (lapping tape) with fine abrasive particles such asM20000, WA10000 or K10000. It is possible to use an abrasive wheel(lapping wheel) in place of or in combination with the abrasive tape(lapping tape). In case where frequent replacement is needed, theabrasive tape (lapping tape) alone is used.

(2) Rotary Treatment

A rotary wheel having air-bleeding grooves (standard: width of 1 inch(25.4 mm); diameter of 60 mmφ; air-bleeding groove width of 2 mm; grooveangle of 45 degrees, manufactured by KYOWA SEIKO Co., Ltd.) is rotatedat a constant revolution rate (usually 200 to 3,000 rpm; standard: 1,100rpm) in a direction opposite to the feeding direction of the magneticlayer, while being allowed to be in contact with the magnetic layer ofthe magnetic tape at a constant contact angle (standard: 90 degrees).Thus, the surface of the magnetic layer is treated.

(3) Tissue treatment

Tissue (a woven fabric, for example, Traysee manufactured by Toray) isfed at a constant rate (standard: 14.0 mm/min.) by rotary rods, in adirection opposite to the feeding direction of the magnetic tape, so asto clean the surfaces of the backcoat layer and the magnetic layer ofthe magnetic tape, respectively.

A cassette tape including a magnetic tape of the present invention showsa high S/N with respect to optical servo signals, and thus is excellentin servo tracking performance. Therefore, such a cassette tape can beused as a backup tape for a hard disc drive, with high reliability.

EXAMPLES

The present invention will be explained in detail by way of thefollowing Examples, which do not limit the scope of the invention in anyway. In Examples and Comparative Examples, “parts” are “parts byweight”, unless otherwise specified.

Example 1 Components of a Paint for a Primer Layer

(1) Iron oxide powder (particle size: 0.11 × 0.02 μm) 68 parts α-Alumina(particle size: 0.07 μm)  8 parts Carbon black (particle size: 25 nm; 24parts oil absorption: 55 g/cc) Stearic acid 2.0 parts  Vinylchloride-hydroxypropyl acrylate copolymer 8.8 parts  (—SO₃Na groupcontent: 0.7 × 10⁻⁴ eq./g) Polyesterpoyurethane resin 4.4 parts  (Tg:40° C., —SO₃Na group content: 1 × 10⁻⁴ eq./g) Cyclohexanone 25 partsMethyl ethyl ketone 40 parts Toluene 10 parts (2) Butyl stearate 1 partCyclohexanone 70 parts Methyl ethyl ketone 50 parts Toluene 20 parts (3)Polyisocyanate 4.4 parts  (Colonate L manufactured by NipponPolyurethane) Cyclohexanone 10 parts Methyl ethyl ketone 15 partsToluene 10 parts

<Components of a Paint for a Magnetic Layer>

(A) Ferromagnetic iron metal powder 100 parts (Co/Fe: 30 atomic %,Y/(Fe + Co): 3 atomic %, Al/(Fe + Co): 5 wt. %, Ca/Fe: 0; σs: 155A·m²/kg, Hc: 188.2 kA/m, pH: 9.4, major axis length: 0.10 μm) Vinylchloride-hydroxypropyl acrylate copolymer 12.3 parts (—SO₃Na groupcontent: 0.7 × 10⁻⁴ eq./g) Polyesterpolyurethane resin 5.5 parts (—SO₃Nagroup content: 1 × 10⁻⁴ eq./g) α-Alumina (particle size: 0.12 μm) 8parts α-Alumina (particle size: 0.07 μm) 2 parts Carbon black (particlesize: 75 nm; 1.0 part DBP oil absorption: 72 cc/100 g) Methyl acidphosphate 2 parts Palmitic acid amide 1.5 parts n-Butyl stearate 1.0part Tetrahydrofuran 65 parts Methyl ethyl ketone 245 parts Toluene 85parts (B) Polyisocyanate (Colonate L manufactured by 2.0 parts NipponPolyurethane Kogyo K.K.) Cyclohexanone 167 parts

A paint for a primer layer was prepared by kneading the components ofGroup (1) with a kneader, adding the components of Group (2) to themixture, and stirring them, dispersing the mixture in a sand mill inresidence time of 60 minutes, and adding the components of Group (3),followed by stirring and filtering the mixture.

Separately, a paint for a magnetic layer was prepared by kneading thecomponents of Group (A) with a kneader, dispersing the mixture in a sandmill in residence time of 45 minutes, and adding the components of Group(B), followed by stirring and filtering the mixture.

The paint for primer layer was applied on a nonmagnetic support composedof a polyethylene naphthalate film (thickness of 6.2 μm, MID=6.08 GPa,MD/TD=1.1; manufactured by TEIJIN) so that the primer layer could have athickness of 1.8 μm after dried and calendered, and then, the paint formagnetic layer was applied on the primer layer by a wet-on-wet method sothat the magnetic layer could have a thickness of 0.15 μm after orientedin a magnetic field, dried and calendered. After the orientation in themagnetic field, the magnetic layer was dried with a drier to obtain amagnetic sheet. The orientation in the magnetic field was carried out byarranging N-N opposed magnets (5 kG) in front of the drier, i.e.,arranging two N-N opposed magnets (5 kG) spaced 50 cm from each other,at a position 75 cm before a position where the dryness of the layer wasconfirmed by one's fingers within the drier. The coating rate was 100m/min.

<Components of a Paint for a Backcoat Layer>

Carbon black (particle size: 25 nm) 78 parts (41.5 wt. %) Carbon black(particle size: 350 nm) 10 parts (5.3 wt. %) [Total carbon black: 88parts (46.8 wt. %)] Red iron oxide A 10 parts (5.3 wt. %) (particlesize: 0.1 μm) Red iron oxide B 2 parts (1.1 wt. %) (particle size: 0.27μm) [Total nonmagnetic powder: 100 parts (53.2 wt. %)] Nitrocellulose(NC) 44 parts (23.4 wt. %) Polyurethane resin 31 parts (16.4 wt. %)(containing —SO₃Na groups) Cyclohexanone 260 parts Toluene 260 partsMethyl ethyl ketone 525 parts

The components of a paint for a backcoat layer were dispersed in a sandmill in residence time of 45 minutes and a polyisocyanate (13 parts, 6.9wt. %) was added to the mixture to obtain a paint for backcoat layer.After filtration, the paint was coated on a surface of the abovemagnetic sheet opposite to the magnetic layer so that the backcoat layercould have a thickness of 0.5 μm after dried and calendered, and then,the backcoat layer was dried to finish the magnetic sheet.

The magnetic sheet obtained was planished by seven-stage calenderingusing metal rolls at a temperature of 100° C. under a linear pressure of147 kN/m (150 kgf/cm), and wound onto a core and aged at 70° C. for 72hours. The magnetic sheet was cut into a plurality of magnetic tapeswith a width of ½ inch. Then, the magnetic tape was subjected to LRTtreatment under the following conditions. Then, pits for optical servowere formed on the backcoat layer, using the apparatus for forming andcleaning optical servo tracks shown in FIG. 7. The backcoat layer wascleaned by spraying solid CO₂ thereto. The magnetic tape thus obtainedwas set in a cartridge to provide a tape for use in a computer. Theapparatus for forming and cleaning optical servo tracks, and thetreatment using the same apparatus will be described later.

<LRT (Lapping/Rotary/Tissue) Treatment>

(1) Lapping

An abrasive tape (lapping tape) was moved by rotary rolls at a rate of14.4 cm/min. in a direction opposite to the feeding direction of themagnetic tape (400 m/min.), while being pressed down from above by aguide block (4) to contact with the surface of the magnetic layer of themagnetic tape. In this step, the magnetic layer was polished while theunwinding tension of the magnetic tape being maintained at 100 g and thetension of the lapping tape, at 250 g.

(2) Rotary Aluminum Wheel Treatment

An aluminum rotary wheel which had a width of 1 inch. (25.4 mm), adiameter of 60 mm, and air-bleeding grooves with a width of 2 mm (theangle of groove: 45 degrees, manufactured by KYOWA SEIKO Co., Ltd.;) wasrotated at a revolution rate of 1,100 rpm in a direction opposite to thefeeding direction of the magnetic tape, in contact with the magneticlayer of the magnetic tape at a contact angle of 90 degrees. Thus, thesurface of the magnetic layer was treated.

(3) Tissue Treatment

A tissue (a woven fabric: Toraysee manufactured by Toray) was fed at arate of 14.0 mm/min. in a direction opposite to the feeding direction ofthe magnetic tape by rotary bars to clean the surfaces of the backcoatlayer and the magnetic layer of the magnetic tape.

Hereinafter, the treatments using the apparatus for forming and cleaningoptical servo tracks, as mentioned above, are described.

As shown in FIG. 7, the apparatus for forming and cleaning optical servotracks comprises a tape-feeding mechanism (11) for feeding a reeledmagnetic tape (1) in a predetermined direction; an optical servotrack-forming unit (12) for forming pits for optical servo on thesurface of the backcoat layer of the fed magnetic tape (1) byirradiation with laser beams; a cleaning unit (13) for cleaning thesurface of the backcoat layer after the formation of the pits; and atape-winding mechanism for winding the magnetic tape (1) after cleaning.

In the cleaning unit (13), there are arranged a CO₂-spraying sectionequipped with a spray nozzle (15) for spraying solid CO₂ onto the abovepits and their peripheries; a sucking section equipped with a suctionnozzle (a sucking means) (16) for sucking the burnt residues which havebeen blown by the solid CO₂-spraying and adhered to the pits and theirperipheries; and a wiping section (17) for wiping the surface of thebackcoat layer with a tissue cleaner after the suction of the burntresidues.

The spray nozzle (15) provided in the CO₂-spraying section hasCO₂-spraying orifices (15 a) which correspond to a pattern for tracks ofpits for optical servo, arranged in the widthwise direction of themagnetic tape (1), as shown in FIG. 3. The spray nozzle (15) is setabove the surface of the backcoat layer (2) of the magnetic tape (1),inclining by 30° thereto (see FIG. 3). The solid CO₂ is obliquelysprayed onto a CO₂-receiving portion (B) of the backcoat layer (2),toward a direction reverse to the tape-running direction. The suctionnozzle (16) provided in the sucking section has suction ports (16 a)which are located in the vicinity of the above CO₂-receiving portion (B)of the backcoat layer. The nozzle (16) sucks the burnt residues whichhave been separated from the surface of the backcoat layer by thespraying of the solid CO₂, through its suction ports (16 a) and removesthem from the surface of the backcoat layer.

The wiping section (17) comprises tissue cleaners (18, 19) arranged soas to contact with the surfaces of the magnetic layer and the backcoatlayer of the magnetic tape (1), and a respective pair of rollers (20,21) which hold and wind the tissue cleaners (18, 19) at predeterminedspeeds. The tissue cleaners (18, 19) are pressed against the surfaces ofthe magnetic layer and the backcoat layer of the magnetic tape (1),respectively, to wipe and remove unwanted particles adhered thereto.

In addition, the apparatus shown in FIG. 7 is provided withtension-controlling means as follows. That is, a first suction roll (22)is arranged between the optical servo track-forming unit (12) and thesuction nozzle (16); a second suction roll (23), between the spraynozzle (15) and the wiping section (17); and a third suction roll (24),between the wiping section (17) and the winding unit (14). A tension arm(25) is arranged between the tape-feeding mechanism (11) and the opticalservo track-forming unit (12); and a tension arm (26), between the thirdsuction roll (24) and the winding mechanism (14). The tension arms (25,26) are to control the tension of the magnetic tape (1). Further, atension detector (27) is arranged between the second suction roll (23)and the spray nozzle (15); and a tension detector (28), between thesecond suction roll (23) and the wiping section (17). The tensiondetectors (27, 28) are provided to detect the tension of the magnetictape (1) and control the tension thereof. Thus, an optimal tension isseparately applied to the magnetic tape (1) at each of the optical servotrack-forming unit (12), and the CO₂-spraying section and the wipingsection (17) in the cleaning unit (13), by interrupting the transmissionof the tension of the magnetic tape (1) via each of the suction rolls(22 to 24), and feedback-controlling the values of the tension detectors(27, 28) via a servo motor which rotates each of the suction rolls (22to 24).

In the Examples of the present invention, the above apparatus was usedto run the magnetic tape at 10 m/sec. while maintaining the tension ofthe magnetic tape at 150 g, so as to form a pattern of pits for opticalservo as described below, on the magnetic tape, to spray solid CO₂, andto clean the tape by removing the burnt residues.

<Formation of Pattern of Pits for Optical Servo>

In the optical servo track-forming unit (12) of the apparatus shown inFIG. 7, the surface of the backcoat layer of the magnetic tape (1) wasirradiated with laser beams to form pits for optical servo thereon. As apattern of pits for optical servo, tracks of pits were formed as fourbands each having a width of about 0.4 mm, and such four bands werewidthwise arranged on the tape which had a width of 12.64 mm, as shownin FIG. 6.

<Solid CO₂-Spraying Treatment>

Next, the solid CO₂-spraying nozzle (15) and the suction nozzle (16)were used to remove substantially all of burnt residues which had beenformed by the above irradiation with laser beams. The spray nozzle (15)was inclined by 30° relative to the surface of the backcoat layer, asdescribed above.

<Cleaning Treatment>

Finally, the tissue cleaners (18, 19) provided in the wiping section(17) were used to completely remove the residual burnt residues. Thus,the finished magnetic tape could have a Brδ of 0.045 μTm (the product ofthe residual magnetic flux density and the thickness of the magneticlayer in the tape lengthwise direction), and a coercive force He of 192kA/m.

Example 2

A magnetic tape was obtained substantially in the same manner as inExample 1, except that the calendering conditions were changed, that is,the temperature and the linear pressure were changed from 100° C. and147 kN/m (150 kgf/cm) to 90° C. and 294 kN/m (300 kgf/cm).

Example 3

A magnetic tape was obtained substantially in the same manner as inExample 1, except that the calendering conditions were changed, that is,the temperature and the linear pressure were changed from 100° C. and147 kN/m (150 kgf/cm) to 120° C. and 294 kN/m (300 kgf/cm).

Example 4

A magnetic tape was obtained substantially in the same manner as inExample 1, except that the thickness of the backcoat layer was changedfrom 0.5 μm to 0.4 μm.

Example 5

A magnetic tape was obtained substantially in the same manner as inExample 1, except that the thickness of the backcoat layer was changedfrom 0.5 μm to 0.6 μm.

Example 6

A magnetic tape having a total thickness of 5.7 μm, Brδ of 0.030 μTm,and a coercive force He of 192 kA/m was obtained substantially in thesame manner as in Example 1, except that a nonmagnetic support with athickness of 4.0 μm, a primer layer with a thickness of 1.0 μm and amagnetic layer with a thickness of 0.1 μm were used, and that thethickness of the backcoat layer was changed from 0.5 μm to 0.6 μm.

Examples 7 to 10

Magnetic tapes were obtained substantially in the same manner as inExample 1, except that backcoat layers having the composition ratiosshown in Table 1 were used.

Reference Example 1

A magnetic tape was obtained substantially in the same manner as inExample 1, except that the solid CO₂-spraying treatment was omitted.

Comparative Examples 1 to 6

Magnetic tapes were obtained substantially in the same manner as inExample 1, except that backcoat layers having the thickness and thecomposition ratios shown in Table 2 were used.

Comparative Example 7

A magnetic tape having a total thickness of 5.7 μm was obtainedsubstantially in the same manner as in Comparative Example 3, exceptthat a nonmagnetic support with a thickness of 4.0 μm, a primer layerwith a thickness of 1.0 μm and a magnetic layer with a thickness of 0.1μm were used, and that the thickness of the backcoat layer was changedfrom 0.5 μm to 0.6 μm.

TABLE 1 Ex. 1 Ex. 7 Ex. 8 Ex. 9 Ex. 10 Small particle size CB 41.5 wt. %40.0 wt. % 42.1 wt. % 47.0 wt. % 47.3 wt. % Particle size (nm) 25   25  25   17   25   Large particle size CB  5.3 wt. %  5.0 wt. %  7.4 wt. % 2.5 wt. %  6.8 wt. % Particle size (nm) 350    370    370    280   280    Ratio of large particle 11.3 wt. % 11.1 wt. % 11.2 wt. % 5.0 wt.% 12.5 wt. % size CB*¹ Ratio of CB*² 88.0 wt. % 90.0 wt. % 89.9 wt. %89.3 wt. % 90.9 wt. % Red iron oxide A  5.3 wt. %  5.0 wt. %  4.9 wt. % 5.4 wt. %  4.5 wt. % Particle size (μm) 0.1 0.1 0.1 0.1 0.1 Red ironoxide B  1.1 wt. % —  1.0 wt. %  1.5 wt. %  0.9 wt. % Particle size (μm) 0.27  0.20  0.20  0.20 BaSO₄ — — — — — Particle size (μm) Ratio ofnonmagnetic 53.2 wt. % 50.0 wt. % 55.4 wt. % 55.4 wt. % 59.5 wt. %powder NC 23.4 wt. % 25.0 wt. % 22.3 wt. % 22.3 wt. % 20.3 wt. %Polyurethane 16.4 wt. % 17.5 wt. % 14.8 wt. % 14.9 wt. % 13.5 wt. %Crosslingking agent  6.9 wt. %  7.5 wt. %  7.4 wt. %  7.4 wt. %  6.8 wt.% Notes: *¹The ratio of large particle size carbon black in a whole ofcarbon black. *²The ratio of carbon black in nonmagnetic powder.

TABLE 2 Com. Ex. 1 Com. Ex. 2 Com. Ex. 3 Com. Ex. 4 Com. Ex. 5 Com. Ex.6 Small particle size CB 38.6 wt. % 33.8 wt. % 35.9 wt. % 42.8 wt. %38.7 wt. % 38.7 wt. % Particle size (nm) 17 17 17 17 17 17 Largeparticle size CB  1.6 wt. % — — 0.09 wt. %  7.8 wt. %  3.9 wt. %Particle size (nm) 270 280 280 280 Ratio of large particle  4.0 wt. % ——  2.0 wt. % 16.8 wt. %  9.2 wt. % size CB*¹ Ratio of CB*² 90.3 wt. %100.0 wt. %  100.0 wt. %  99.7 wt. % 95.9 wt. % 87.8 wt. % Red ironoxide A — — — — —  3.9 wt. % Particle size (μm) 0.1 Red iron oxide B — —— 0.04 wt. % 0.03 wt. %  0.1 wt. % Particle size (μm) 0.2 0.2 0.2 BaSO₄ 4.3 wt. % — — —  1.9 wt. %  1.9 wt. % Particle size (μm) 0.05 0.05 0.05Ratio of nonmagnetic 44.5 wt. % 33.8 wt. % 35.9 wt. % 43.0 wt. % 48.5wt. % 48.5 wt. % powder NC 27.9 wt. % 20.2 wt. % 19.6 wt. % 42.8 wt. %38.7 wt. % 38.7 wt. % Polyurethane 18.4 wt. % 33.8 wt. % 32.7 wt. % 12.9wt. % 11.6 wt. % 11.6 wt. % Crosslingking agent  9.3 wt. % 12.2 wt. %11.8 wt. %  1.3 wt. %  1.2 wt. %  1.2 wt. % Notes: *¹The ratio of largeparticle size carbon black in a whole of carbon black. *²The ratio ofcarbon black in nonmagnetic powder.

Example 11

Pits for optical servo were formed on the backcoat layer of a magnetictape, using an apparatus for forming and cleaning optical servo tracksshown in FIG. 9. After that, a tape for a computer was obtainedsubstantially in the same manner as in Example 1, except that acontact-removing treatment using a raised fabric or the like, and acleaning treatment, as described below, were carried out on the magnetictape.

The apparatus shown in FIG. 9 and the treatments using this apparatusare explained.

The apparatus used in Example 11 comprises, as shown in FIG. 9, atape-feeding mechanism (11) for feeding a reeled magnetic tape (1) in apredetermined direction; an optical servo track-forming unit (12) forforming pits for optical servo on the surface of the backcoat layer ofthe fed magnetic tape (1) by irradiation with laser beams; a cleaningunit (13) for cleaning the surface of the backcoat layer (2) after theformation of the pits; and a tape-winding mechanism (14) for winding themagnetic tape (1) after cleaning.

The cleaning unit (13) comprises a contact-removing section for allowingraised cloth such as a raised fabric or woven or nonwoven fabric havingraising fibers thereon, to contact with the surface of the backcoatlayer, in order to clean the surface of the backcoat layer, and a wipingsection (17) for wiping the surfaces of the backcoat layer and themagnetic layer with tissue cleaners.

In the contact-removing section (15 b), a wrapped drum (30) as shown inFIG. 8 is arranged. The wrapped drum (30) comprises a rotary drum (31)(having a diameter of 100 mm in this Example) which is rotated in adirection reverse to the running direction of the magnetic tape (1) andis wrapped with raised cloth (32) at its circumference. A pair of guiderollers (41, 41) are arranged before and after the wrapped drum (30) soas to allow the drum (30) to contact with the surface of the backcoatlayer of the magnetic tape (1) in a predetermined condition.

The wiping section (17) includes tissue cleaners (18, 19) which arearranged so as to contact with the surfaces of the magnetic layer andthe backcoat layer of the magnetic tape (1), respectively, and two pairsof rollers (20, 21) which hold the tissue cleaners (18, 19),respectively, so that the tissue cleaners can be wound at predeterminedvelocities. The tissue cleaners (18, 19) are pressed against thesurfaces of the magnetic layer and the backcoat layer, respectively, soas to wipe and remove the unwanted particles thereon.

In addition, the apparatus shown in FIG. 9 is provided with means forcontrolling the tension of the tape described below. That is, a firstsuction roll (22) is arranged between the optical servo track-formingunit (12) and the contact-removing section (15 b); a second suction roll(23), between the contact-removing section (15 b) and the wiping section(17); and a third suction roll (24), between the wiping section (17) andthe winding mechanism (14). A tension arm (25) is arranged between thetape-feeding mechanism (11) and the optical servo track-forming unit(12); and a tension arm (26), between the third suction roll (24) andthe winding mechanism (14). The tension arms (25, 26) are provided tocontrol the tension of the magnetic tape (1). Further, a tensiondetector (27) is arranged between the second suction roll (23) and thecontact-removing section (15 b); and a tension detector (28), betweenthe second suction roll (23) and the wiping section (17). The tensiondetectors (27, 28) are provided to detect the tension of the magnetictape (1) and control the tension thereof. An optimal tension isseparately applied to the magnetic tape (1) at each of the optical servotrack-forming unit (12), and the contact-removing section (15 b) and thewiping section (17) in the cleaning unit (13), by interrupting thetransmission of the tension of the magnetic tape (1) via each of thesuction rolls (22 to 24), and feedback-controlling the values of thetension detectors (27, 28) via a servo motor which rotates each of thesuction rolls (22 to 24).

In the Examples of the present invention, the above apparatus was usedto run the magnetic tape at 10 m/sec. while maintaining the tension ofthe magnetic tape constant, so as to form a pattern of pits for opticalservo on the magnetic tape, to treat the magnetic tape by contacting thewrapped drum (30), and to wipe the same with the tissue cleaners (18,19) for cleaning.

<Formation of Pattern of Pits for Optical Servo>

In the optical servo track-forming unit (12) of the apparatus shown inFIG. 9, the surface of the backcoat layer of the magnetic tape (1) wasirradiated with laser beams so as to form a predetermined pattern ofpits for optical servo thereon. As the pattern of pits for opticalservo, tracks of pits were formed as four bands each having a width ofabout 0.4 mm, and such four bands were widthwise arranged on the tapewhich had a width of 12.64 mm, as shown in FIG. 6.

<Contact-Removing Treatment using Wrapped Drum>

Next, in the contact-removing section (15 b), the wrapped drum (30) wasrotated at a rate of 314 radian/sec. (3,000 rpm) in a direction reverseto the tape-running direction, while the raised cloth (32) wrapping theouter circumference of the drum (30) was allowed to contact with thesurface of the backcoat layer (2) of the magnetic tape (1) under atension of 2.0 N to remove substantially all of the burnt residues whichhad formed by baking with laser beams in the step of forming the servopattern, from the interiors of the pits and their peripheries on thebackcoat layer. As the raised cloth (32) wrapping the drum (30), velveton which 2.5 mm yarns obtained by twisting 4 cotton single fibers havinga diameter of 4 μm were flocked was used. The tension applied on theside of the inlet was 86 g, and that on the side of the outlet, 208 g.The contact angle between the wrapped drum (30) and the magnetic tape(1) was 120°.

<Cleaning Treatment>

Finally, the tissue cleaners (18, 19) provided in the wiping section(17) were used to completely remove the residual burnt residues. Thus,the finished magnetic tape could have a Brδ of 0.045 μTm, and a coerciveforce He of 192 kA/m. The average reflectance of the magnetic tape was9.0%; the rate of fluctuation thereof, 3.0%; the surface roughness Rathereof, measured with AFM, 25.1 nm; and the half width of Ra, 3.3 nm.The S/N of the servo signal of Example 11 was 1.5 dB, on the assumptionthat the S/N of the servo signal of Reference Example 2 was 0 dB, and itwas 6.1 dB, on the assumption that the S/N of the servo signal ofComparative Example 1 was 0 dB.

Example 12

A magnetic tape was obtained substantially in the same manner as inExample 11, except that the contact angle between the magnetic tape (1)and the wrapped drum (30) was changed to 90°.

Example 13

A magnetic tape was obtained substantially in the same manner as inExample 11, except that the rotation velocity of the wrapped drum (30)was changed to 188.4 radian/sec. (1,800 rpm). The tension of the tape onthe side of the inlet was 95 g, and that on the side of the outlet, 188g, in the step of the contact-removing treatment (treatment at thecontact-removing section).

Example 14

A magnetic tape was obtained substantially in the same manner as inExample 11, except that the tension of the tape being subjected to thecontact-removing treatment with the wrapped drum was changed to 1.8 N.The tension of the tape on the side of the inlet was 80 g, and that onthe side of the outlet, 188 g, in the step of the contact-removingtreatment.

Example 15

A magnetic tape having a total thickness of 5.7 μm, a Brδ of 0.030 μTm,and a coercive force of 192 kA/m was obtained substantially in the samemanner as in Example 11, except that a nonmagnetic support with athickness of 4.0 μm, a primer layer with a thickness of 1.0 μm and amagnetic layer with a thickness of 0.1 μm were used, and that thethickness of the backcoat layer was changed from 0.5 μm to 0.6 μm.

Examples 16 to 19

Magnetic tapes were obtained substantially in the same manner as inExample 11, except that raised fabrics, or woven or nonwoven clothshaving raising fibers thereon, shown in Table 3, were used as the raisedcloth, and that the number of wrapped drums used were changed as shownin Table 8.

Reference Example 2

A magnetic tape was obtained substantially in the same manner as inExample 11, except that the contact-removing treatment using the wrappeddrum (30) was omitted. The reflectance on the backcoat layer of theresultant magnetic tape was 8.5%; the rate of fluctuation thereof, 4.0%;the surface roughness Ra thereof, measured with AFM, 25.2 nm; and thehalf width of Ra, 4.5 nm.

TABLE 3 Ex. 11-15 Ex. 16 Ex. 17 Ex. 18 Ex. 19 Raised fabric CottonCotton Rayon Polyester Polyester pile long pile short short short fiberlong fiber fiber fiber fiber Kind of fiber Cotton Cotton Rayon PolyesterPolyester Diameter of 4 μm 4 μm 5 μm 2 μm 10 μm* single fiber Number of2 4 1 1 1 fibers twisted Length of fiber 2.5 mm 1.65 mm 1.5 mm 0.5 mm 4mm *The tip end of the single fiber was split into 8 pieces.

The measurement and the evaluation were conducted as follows.

<Reflectance>

The reflectance on the flat portion of a magnetic tape was evaluatedusing a spectrometer (UNISOF), on condition that the incident angle was20°, and the reflection angle, 20°. A light emitting diode (or LED) of awavelength of 880 nm was used as a light source. The spot diameter was100 μm. The reflectance was measured at 400 points per 40 mm of themagnetic tape to determine the average reflectance and the maximum rateof fluctuation thereof. The average reflectance was a simple averagevalue of the reflectance, and the maximum rate of fluctuation was thepercentage of a value which was found by dividing the maximum of thedeviation from the average reflectance by the average reflectance. Thereflectance on the flat portion of the magnetic tape which had been run,and the maximum rate of fluctuation thereof were measured by running themagnetic tape twice with a LTO drive, and cutting the magnetic tape forthe measurement.

<Evaluation of Surface Roughness Ra with AFM>

The average surface roughness Ra of a magnetic tape was measured usingan AFM (Dimension TM 3100 manufactured by Digital-Instrument Co., Ltd.).The scanning mode was a tapping mode AFM. In the tapping mode, acantilever equipped at its tip end with a probe was vibrated with arounda resonant frequency (about 50 to about 500 kHz) using a piezo-vibrator,while the probe was being allowed to intermittently and softly touch (ortap) the surface of the tape sample so as to scan the tape. A change inthe amplitude of the cantilever due to the unevenness of the surface ofthe sample was evaluated using laser beams. The field of view for themeasurement was 40 μm×40 μm. The fluctuation of the surface roughness Radepending on a site of the magnetic tape was determined from the halfwidth of the fluctuation of Ra as follows: the surface roughness Ra wasmeasured at 100 points which were spaced at regular intervals per 40 mmlength of the magnetic tape, and Ra at each point was plotted on theaxis of abscissa, and the frequency (1 nm pitch), on the axis ofordinate, so that the half width of the fluctuation of Ra was determinedfrom the resultant graph.

<S/N of Servo Signal on Servo Track>

Light with a center wavelength of 880 nm was caused to emit onto thebackcoat layer at an incident angle of 20°, and the S/N of a servosignal was measured from the reflecting light, using the servosignal-measuring section of a floptical drive. The S/N of the servosignals of Examples 1 to 10, Reference Example 1 and ComparativeExamples 2 to 7 were represented as relative values based on the S/N ofComparative Example 1 as a standard (0 dB). The S/N of the servo signalsof Examples 11 to 19 were represented as relative values based on theS/N of Reference Example 2 as a standard (0 dB).

<Measurement of Error Rate>

The error rate (or ERT) was measured by recording and reproducingsignals on and from a magnetic tape (recording wavelength: 0.37 μm)using a LTO drive which was improved so as to be used on a thinner tape.The ERT was a value obtained in the test mode.

<Evaluation of Magnetic Properties>

The magnetic properties of a magnetic layer and ferromagnetic powderwere evaluated using a vibration sample magnetometer (manufactured byToei Kogyo Co., Ltd.). The external magnetic field was 1.28 MA/m (16kOe).

The results of the evaluation of the magnetic tapes of Examples 1 to 10and Comparative Examples 1 to 7 are shown in Tables 4 to 7.

TABLE 4 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Reflectance (initial) Av.reflectance (%) 9.0 10.2 11.5 8.8 9.5 Rate of 3.0 3.4 5.0 3.5 2.8fluctuation (%) Reflectance after twice tape-running: Av. reflectance(%) 9.2 9.8 10.0 8.6 9.4 Rate of 3.5 3.8 7.5 3.7 3.1 fluctuation (%)Ratio of nonmagnetic 53.2 wt. 53.2 wt. 53.2 wt. 53.2 wt. 53.2 wt. powderSurface roughness with AFM (initial) Ra (nm) 25.2 23.4 21.5 29.5 24.1Half width of Ra 3.0 3.8 4.8 4.1 2.7 (nm) Surface roughness after twicetape- running: Ra (nm) 25.1 23.8 25.2 29.5 23.9 Half width of Ra 3.3 4.08.5 4.5 3.0 (nm) Servo signal (initial) S/N (relative value) 6.1 6.1 5.05.4 6.6 Servo signal after twice tape-running: S/N (relative value) 5.55.5 2.6 5.0 6.2 Error rate (initial) × 0.5 — — — — 10⁻⁸

TABLE 5 Ex. 6 Ex. 7 Ex. 8 Ex. 9 Ex. 10 Reflectance (initial) Av.reflectance (%) 9.1 8.5 10.5 12.3 14.9 Rate of 3.1 4.5 4.2 3.2 4.5fluctuation (%) Reflectance after twice tape-running: Av. reflectance(%) 9.1 8.6 10.4 11.2 13.4 Rate of 3.6 5.0 4.7 4.9 5.0 fluctuation (%)Ratio of nonmagnetic 53.2 wt. 50.0 wt. 55.4 wt. 55.4 wt. 59.5 wt. powderSurface roughness with AFM (initial) Ra (nm) 25.0 22.5 27.5 24.7 29.4Half width of Ra 2.9 4.9 4.4 3.9 4.7 (nm) Surface roughness after twicetape- running: Ra (nm) 24.9 23.1 27.2 28.2 29.9 Half width of Ra 3.1 4.04.5 5.5 5.0 (nm) Servo signal (initial) S/N (relative value) 6.0 4.1 5.37.2 6.5 Servo signal after twice tape-running: S/N (relative value) 5.43.7 4.8 4.9 5.6

TABLE 6 Ref. Com. Com. Com. Com. Ex. 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4Reflectance (initial) Av. reflectance (%) 8.5 7.7 6.8 7.0 7.4 Rate of4.0 10.5 10.4 10.0 10.4 fluctuation (%) Reflectance after twicetape-running: Av. reflectance (%) 8.7 7.2 6.4 6.8 7.2 Rate of 12.5 15.616.1 15.4 13.9 fluctuation (%) Ratio of nonmagnetic 53.2 wt. 44.5 wt.33.8 wt. 35.9 wt. 43.0 wt. powder Surface roughness with AFM (initial)Ra (nm) 25.2 19.7 32.4 25.6 21.9 Half width of Ra 4.5 7.1 10.5 7.0 7.7(nm) Surface roughness after twice tape- running: Ra (nm) 25.1 19.9 33.127.2 23.1 Half width of Ra 7.2 8.3 12.6 8.2 8.0 (nm) Servo signal(initial) S/N (relative value) 4.6 0.0 −0.5 −0.2 −0.1 Servo signal aftertwice tape-running: S/N (relative value) −0.2 −2.0 −2.7 −2.2 −1.5 Errorrate (initial) × 1200 — — — — 10⁻⁸

TABLE 7 Com. Ex. 5 Com. Ex. 6 Com. Ex. 7 Reflectance (initial) Av.reflectance (%) 8.0 7.8 7.1 Rate of 8.2 8.6 10.4 fluctuation (%)Reflectance after twice tape-running: Av. reflectance (%) 8.1 7.8 6.7Rate of 9.8 9.9 16.2 fluctuation (%) Ratio of nonmagnetic 48.5 wt. 48.5wt. 35.9 wt. powder Surface roughness with AFM (initial) Ra (nm) 22.121.9 25.9 Half width of Ra 7.5 7.7 7.2 (nm) Surface roughness aftertwice tape- running: Ra (nm) 22.0 22.3 27.9 Half width of Ra 7.6 7.8 8.1(nm) Servo signal (initial) S/N (relative value) 1.2 0.9 −0.3 Servosignal after twice tape-running: S/N (relative value) 0.5 0.3 −2.5

As is apparent from the results of Examples 1 to 10 and ComparativeExamples 1 to 7 shown in Tables 4 to 7, the magnetic tapes were high inthe initial S/N of the servo signals, and also high in the S/N thereoffound after the magnetic tapes had been run twice, when their averagereflectances were 8.5% or higher on the flat portions, and their maximumcoefficients of fluctuation of reflectance on the flat portions,depending on positions of the magnetic tapes, i.e., [maximum of theabsolute value of (reflectance−average reflectance)]×100/(averagereflectance), were 10% or lower. Also, as is apparent from the resultsof Example 1 and Reference Example 1, by carrying out the solid CO₂spraying treatment, the error rate was decreased and the S/N of theservo signal found after the magnetic tape had been run twice wasincreased. Thus, this treatment is found to be effective to remove theburnt residues in the pits of the backcoat layers.

The results of the evaluation of the magnetic tapes of Examples 11 to 19and Reference Example 2 are shown in Table 8.

TABLE 8 Ex. 11 Ex. 12 Ex. 13 Ex. 14 Ex. 15 Error rate (initial) × 10⁻⁸0.5 1.0 2.0 5 0.6 Number of wrapped 1 1 1 1 1 drums Ref. Ex. 16 Ex. 17Ex. 18 Ex. 19 Ex. 2 Error rate (initial) × 10⁻⁸ 0.5 2.0 1.0 0.5 1200Number of wrapped 2 4 2 2 0 drums

As is apparent from the results of Examples 11 to 19 and ReferenceExample 2 shown in Table 8, the magnetic tapes having low error ratescan be obtained by carrying out the step of allowing the raised fabricsor woven or nonwoven cloths having raising fibers thereon to contactwith the surfaces of the backcoat layers of the magnetic tapes, therebyremoving the burnt residues adhered to the pits for optical servo andtheir peripheries on the backcoat layers, in the course of cleaning thesurfaces of the backcoat layers of the magnetic tapes.

In other words, a magnetic tape as follows is high in the initial S/N ofthe servo signal, and also high in the S/N of the servo signal foundafter the magnetic tape has been run twice: that is, such a magnetictape comprises a nonmagnetic support; a magnetic layer which is formedon one surface of the nonmagnetic support; and a backcoat layer whichcontains nonmagnetic powder and a binder and which is formed on theother surface of the nonmagnetic support, having pits for optical servoformed thereon, and the magnetic tape is characterized in that theaverage reflectance on the flat portion of the backcoat layer is 8.5% orhigher, and that the maximum rate of fluctuation of the reflectance onthe flat portion depending on a position of the magnetic tape, i.e.,[maximum of absolute value of (reflectance−averagereflectance)]×100/(average reflectance), is 10% or lower. Further, theerror rate is decreased, and the S/N of the servo signal is increased,by cleaning the backcoat layer of the magnetic tape, i.e., by sprayingsolid CO₂ onto the backcoat layer or by allowing a raised fabric tocontact with the surface of the backcoat layer. Therefore, thesetreatments are effective to remove the burnt residues adhered to thepits of the backcoat layer.

1. A magnetic tape comprising a nonmagnetic support, a magnetic layerwhich is formed on one surface of the nonmagnetic support, and abackcoat layer which comprises a binder and nonmagnetic powdercontaining carbon black as a component, which is formed on the othersurface of the nonmagnetic support, and which has pits for optical servoformed thereon, wherein a content of the nonmagnetic powder in thebackcoat layer is from 50 wt. % to 60 wt. % based on the total weight ofthe nonmagnetic powder and the binder in the backcoat layer; an averagesurface roughness Ra of a flat portion of the backcoat layer, which ismeasured with an atomic force microscope, is 30 nm or less; and anaverage of reflection on a flat portion of the backcoat layer is from8.5% to 14.9%.
 2. The magnetic tape according to claim 1, wherein amaximum rate of fluctuation of the reflectance on the flat portion ofthe backcoat layer depending on a position of the magnetic tape, whichis defined by the following equation, is from 2.8% to 10%:[Maximum of absolute value of (Reflectance−Average ofreflectance)]×100/(Average of reflectance).
 3. The magnetic tapeaccording to claim 1, wherein a half width of fluctuation of the surfaceroughness Ra, depending on a site of the magnetic tape, is 5 nm or less.